U.S. patent application number 11/312369 was filed with the patent office on 2006-06-22 for direct methanol fuel cell.
This patent application is currently assigned to MATSUSHITA ELECTRIC INDUSTRIAL CO., LTD.. Invention is credited to Shinsuke Fukuda, Hideyuki Ueda.
Application Number | 20060134508 11/312369 |
Document ID | / |
Family ID | 36596277 |
Filed Date | 2006-06-22 |
United States Patent
Application |
20060134508 |
Kind Code |
A1 |
Ueda; Hideyuki ; et
al. |
June 22, 2006 |
Direct methanol fuel cell
Abstract
A direct methanol fuel cell of the present invention includes a
unit cell having an electrolyte membrane, an anode on one surface
of the electrolyte membrane, and a cathode on the other surface of
the electrolyte membrane. The anode includes an anode catalyst
layer and an anode diffusion layer. The anode catalyst layer is in
contact with a surface of the electrolyte membrane. The anode
diffusion layer is in contact with a surface of the anode catalyst
layer opposite to the surface of the anode catalyst layer in
contact with the electrolyte membrane. A methanol flux value
J.sub.GDL of the anode diffusion layer and a methanol flux value
J.sub.PEM of the electrolyte membrane satisfy the following
relations: J.sub.GDL=1.times.10.sup.-5 to 5.times.10.sup.-4
mol/(cm.sup.2min.), (i) and
J.sub.PEM.times.J.sub.GDL.ltoreq.1.times.10.sup.-8
[mol/(cm.sup.2min.)].sup.2. (ii)
Inventors: |
Ueda; Hideyuki;
(Ibaraki-shi, JP) ; Fukuda; Shinsuke;
(Moriguchi-shi, JP) |
Correspondence
Address: |
MCDERMOTT WILL & EMERY LLP
600 13TH STREET, N.W.
WASHINGTON
DC
20005-3096
US
|
Assignee: |
MATSUSHITA ELECTRIC INDUSTRIAL CO.,
LTD.
|
Family ID: |
36596277 |
Appl. No.: |
11/312369 |
Filed: |
December 21, 2005 |
Current U.S.
Class: |
429/442 ;
429/449; 429/482; 429/506; 429/532 |
Current CPC
Class: |
H01M 8/0239 20130101;
H01M 8/04197 20160201; H01M 8/1011 20130101; H01M 8/04186 20130101;
Y02E 60/523 20130101; Y02E 60/50 20130101; H01M 4/8605 20130101;
H01M 8/0234 20130101 |
Class at
Publication: |
429/044 ;
429/030; 429/013 |
International
Class: |
H01M 4/94 20060101
H01M004/94; H01M 8/10 20060101 H01M008/10 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 21, 2004 |
JP |
2004-368787 |
Claims
1. A direct methanol fuel cell comprising a unit cell having an
electrolyte membrane, an anode on one surface of said electrolyte
membrane, and a cathode on the other surface of said electrolyte
membrane, said anode comprising an anode catalyst layer and an
anode diffusion layer, said anode catalyst layer being in contact
with a surface of said electrolyte membrane, said anode diffusion
layer being in contact with a surface of said anode catalyst layer
opposite to said surface of said anode catalyst layer in contact
with said electrolyte membrane, wherein a methanol flux value
J.sub.GDL of said anode diffusion layer and a methanol flux value
J.sub.PEM of said electrolyte membrane satisfy the following
relations: J.sub.GDL=1.times.10.sup.-5 to 5.times.10.sup.-4
mol/(cm.sup.2min.), (i) and
J.sub.PEM.times.J.sub.GDL.ltoreq.1.times.10.sup.-8
[mol/(cm.sup.2min.)].sup.2. (ii)
2. The direct methanol fuel cell in accordance with claim 1,
wherein said anode diffusion layer has an air permeability
Q.sub.Air of 200 to 1000 cc/(cm.sup.2min.kPa).
3. The direct methanol fuel cell in accordance with claim 1,
wherein a surface layer having a porous structure is formed on a
surface of said anode diffusion layer, and said surface layer
comprises a water repellent resin fine particle and a water
repellent binder material.
4. The direct methanol fuel cell in accordance with claim 1,
wherein a surface layer having a porous structure is formed on a
surface of said anode diffusion layer, and said surface layer
comprises an electron conductive porous material and a water
repellent binder material.
5. A method for generating power using a direct methanol fuel cell
comprising a unit cell having an electrolyte membrane, an anode on
one surface of said electrolyte membrane, and a cathode on the
other surface of said electrolyte membrane, said anode comprising
an anode catalyst layer and an anode diffusion layer, said anode
catalyst layer being in contact with a surface of said electrolyte
membrane, said anode diffusion layer being in contact with a
surface of said anode catalyst layer opposite to said surface of
said anode catalyst layer in contact with said electrolyte
membrane, said method comprising the steps of: (a) selecting an
anode diffusion layer and an electrolyte membrane such that a
methanol flux value J.sub.GDM of said anode diffusion layer and a
methanol flux value J.sub.PEM of said electrolyte membrane, which
are measured by allowing said anode diffusion layer and said
electrolyte membrane to come into contact with an aqueous solution
having a certain methanol concentration at a certain temperature,
satisfy the following relations: J.sub.GDL=1.times.10.sup.-5 to
5.times.10.sup.-4 mol/(cm.sup.2min.), (i) and
J.sub.PEM.times.J.sub.GDL.ltoreq.1.times.10.sup.-8
[mol/(cm.sup.2min.)].sup.2; (ii) (b) determining a concentration of
methanol to be contained in fuel and a temperature for operating
said fuel cell based on the temperature and the methanol
concentration used for said measurement of said J.sub.GDL and said
J.sub.PEM; and (c) generating power at said temperature determined
in said step (b) by feeding fuel containing methanol at the
concentration determined in said step (b) to said anode.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a direct methanol fuel cell
that uses methanol or an aqueous solution of methanol as the
fuel.
BACKGROUND OF THE INVENTION
[0002] As portable compact electronics such as cell phones,
personal digital assistances (PDAs), notebook computers and
camcorders perform more functions, they consume more electric power
and operate for a longer period of time. In order to satisfy such
increasing power demand and to achieve longer continuous operation,
batteries for portable compact electronics having a higher energy
density are in strong demand.
[0003] Currently, lithium secondary batteries are widely used as
the main power supply for portable compact electronics. Lithium
secondary batteries are expected to have an energy density of about
600 Wh/L by 2006, which is considered as the maximum energy density
for lithium secondary batteries. As an alternative to lithium
secondary batteries, early commercialization of fuel cells having a
solid polymer electrolyte membrane is eagerly awaited.
[0004] Among fuel cells, direct methanol fuel cells (DMFCs) are
attracting attention and being vigorously studied in which a fuel
such as methanol or an aqueous solution of methanol is fed directly
into the fuel cell for power generation without converting the fuel
into hydrogen. This is because methanol has a very high theoretical
energy density and offers advantages of simple system design and
easy storage.
[0005] A single unit cell contained in a direct methanol fuel cell
comprises a membrane electrode assembly (MEA) and separators
disposed on both sides of the MEA. The membrane electrode assembly
(MEA) comprises a solid polymer electrolyte membrane, an anode
attached to one surface of the solid polymer electrolyte membrane,
and a cathode attached to the other surface of the solid polymer
electrolyte membrane. The anode and the cathode each comprise a
catalyst layer and a diffusion layer.
[0006] A direct methanol fuel cell generates electricity (power) by
feeding a fuel (i.e., methanol or an aqueous solution of methanol)
directly into the anode and air to the cathode. In the direct
methanol fuel cell, the following reaction occurs. Anode:
CH.sub.3OH+H.sub.2O.fwdarw.CO.sub.2+6H.sup.++6e.sup.- Cathode:
3/2O.sub.2+6H.sup.++6e.sup.-.fwdarw.3H.sub.2O
[0007] That is, methanol reacts with water at the anode to produce
carbon dioxide, protons and electrons. The protons pass through the
electrolyte membrane to reach the cathode. At the cathode, oxygen
combines with the protons and electrons migrated into the cathode
through an external circuit to produce water.
[0008] In order to achieve commercialization of direct methanol
fuel cells, however, the following problem must be solved.
[0009] Direct methanol fuel cells employ, as the electrolyte
membrane, a perfluoroalkyl sulfonic acid membrane from the
viewpoint of proton conductivity, thermal resistance and resistance
to oxidation. Electrolyte membranes of this type comprise a main
chain of hydrophobic polytetrafluoroethylene (PTFE) and a side
chain of a perfluoro group having hydrophilic sulfonic acid group
fixed at the terminal of the perfluoro group. Accordingly, methanol
having both hydrophilic and hydrophobic parts is a suitable solvent
for a perfluoroalkyl sulfonic acid membrane because methanol can
easily pass through the polymer electrolyte membrane. However, a
phenomenon called "methanol crossover" occurs in which methanol fed
into the anode pass through the electrolyte membrane to the
cathode, without reacting. This methanol crossover not only reduces
the fuel utilization efficiency but also the potential of the
cathode, which significantly degrades power generation
characteristic. This methanol crossover tends to increase as the
methanol concentration and the operating temperature get
higher.
[0010] In order to reduce methanol crossover, in addition to the
development of novel electrolyte membranes, various proposals are
made to modify the structure of anodes.
[0011] For example, in order to reduce methanol crossover at the
upstream side of a fuel flow channel and to prevent supply shortage
of methanol at the downstream side of the fuel flow channel so as
to uniformly supply a fuel to the anode, Japanese Laid-Open Patent
Publication No. 2002-110191 proposes a structure in which the
methanol permeability coefficient of an anode diffusion layer is
higher at the downstream side of the fuel flow channel. The anode
diffusion layer disclosed in Japanese Laid-Open Patent Publication
No. 2002-110191 comprises a carbon paper substrate and a mixed
layer containing carbon black and polytetrafluoroethylene formed on
a surface of the substrate. In order to increase the methanol
permeability coefficient of the anode diffusion layer along the
fuel flow channel, the publication further discloses to reduce the
thickness of the mixed layer, to reduce the weight ratio of the
polytetrafluoroethylene, to reduce the water repellency of the
carbon black, and to increase the porosity and/or pore size of the
carbon black.
[0012] Another problem that must be solved to achieve
commercialization of direct methanol fuel cells is removability of
carbon dioxide (CO.sub.2) gas produced at the anode from the anode
diffusion layer. In other words, the carbon dioxide gas
permeability of anode diffusion layer should be improved. The
carbon dioxide gas produced at the anode passes through the anode
diffusion layer, reaches the flow channel of a separator and then
to the outside. If the anode diffusion layer has low gas
permeability, some of the generated gas might accumulate inside the
diffusion layer, inhibiting the dispersion of fuel into the
catalyst layer. Furthermore, the carbon dioxide gas might gradually
coalesce to form large bubbles, which squeeze the fuel from the
pores of the diffusion layer, reducing the supply amount of fuel to
the anode catalyst layer. As a result, power generation
characteristic at a high current density, which requires a large
amount of fuel, decreases significantly.
[0013] In order to overcome this problem, Japanese Laid-Open Patent
Publication No. 2002-175817 proposes to provide separate
(completely segregated) flow channels for liquid fuel and exhaust
gas on an anode-side plate (i.e., separator), and to impart liquid
permeability and gas impermeability to the area of an anode
diffusion layer that faces the flow channel for liquid fuel, as
well as gas permeability to the area of the diffusion layer that
faces the flow channel for exhaust gas.
[0014] Such conventional structures as described above, however,
cannot provide a direct methanol fuel cell having excellent power
generation characteristic without impairing fuel utilization
efficiency. Many problems still remain.
[0015] Japanese Laid-Open Patent Publication No. 2002-110191 fails
to give adequate consideration to the methanol permeability
coefficient of the anode diffusion layer. That is, the effect of
methanol concentration, the effect of operating temperature
(temperature for power generation) and the balance between the
electrolyte membrane and the methanol permeability coefficient are
not fully discussed. The fuel cell disclosed by the above
publication thus suffers from the problem that the power generation
characteristic degrades significantly at a high current density in
the case of, for example, using highly concentrated methanol or
increasing the operating temperature (temperature for power
generation).
[0016] As for the fuel cell disclosed by Japanese Laid-Open Patent
Publication No. 2002-175817, there is a prospect that the problems
such as the supply of a sufficient amount of fuel and the removal
of carbon dioxide will be solved. The publication, however, fails
to disclose any solution for methanol crossover.
[0017] In view of the foregoing, an object of the present invention
is to provide a direct methanol fuel cell having excellent power
generation characteristic without impairing fuel utilization
efficiency by reducing methanol crossover and ensuring that a
sufficient amount of fuel is supplied to the catalyst layer.
Another object of the present invention is to provide a direct
methanol fuel cell having excellent power generation characteristic
by also improving the removability of carbon dioxide from the anode
catalyst layer.
BRIEF SUMMARY OF THE INVENTION
[0018] The present invention relates to a direct methanol fuel cell
comprising a unit cell having an electrolyte membrane, an anode on
one surface of the electrolyte membrane, and a cathode on the other
surface of the electrolyte membrane, the anode comprising an anode
catalyst layer and an anode diffusion layer, the anode catalyst
layer being in contact with a surface of the electrolyte membrane,
the anode diffusion layer being in contact with a surface of the
anode catalyst layer opposite to the surface of the anode catalyst
layer in contact with the electrolyte membrane, wherein a methanol
flux value J.sub.GDL of the anode diffusion layer and a methanol
flux value J.sub.PEM of the electrolyte membrane satisfy the
following relations: (i) J.sub.GDL=1.times.10.sup.-5 to
5.times.10.sup.-4 mol/(cm.sup.2min.), and (ii)
J.sub.PEM.times.J.sub.GDL.ltoreq.1.times.10.sup.-8
[mol/(cm.sup.2min.)].sup.2.
[0019] In the direct methanol fuel cell, the anode diffusion layer
preferably has an air permeability Q.sub.Air of 200 to 1000
cc/(cm.sup.2min.kPa).
[0020] In the direct methanol fuel cell, preferably, a surface
layer having a porous structure is formed on a surface of the anode
diffusion layer. The surface layer preferably comprises a water
repellent resin fine particle and a water repellent binder
material.
[0021] In another preferred embodiment of the present invention, a
surface layer having a porous structure is formed on a surface of
the anode diffusion layer. The surface layer comprises an electron
conductive porous material and a water repellent binder
material.
[0022] The present invention further relates to a method for
generating power using a direct methanol fuel cell comprising a
unit cell having an electrolyte membrane, an anode on one surface
of the electrolyte membrane, and a cathode on the other surface of
the electrolyte membrane, the anode comprising an anode catalyst
layer and an anode diffusion layer, the anode catalyst layer being
in contact with a surface of the electrolyte membrane, the anode
diffusion layer being in contact with a surface of the anode
catalyst layer opposite to the surface of the anode catalyst layer
in contact with the electrolyte membrane, the method comprising the
steps of: (a) selecting an anode diffusion layer and an electrolyte
membrane such that a methanol flux value J.sub.GDM of the anode
diffusion layer and a methanol flux value J.sub.PEM of the
electrolyte membrane, which are measured by allowing the anode
diffusion layer and the electrolyte membrane to come into contact
with an aqueous solution having a certain methanol concentration at
a certain temperature, satisfy the following relations: (i)
J.sub.GDL=1.times.10.sup.-5 to 5.times.10.sup.-4
mol/(cm.sup.2min.), and (ii)
J.sub.PEM.times.J.sub.GDL.ltoreq.1.times.10.sup.-8
[mol/(cm.sup.2min.)].sup.2; (b) determining a concentration of
methanol to be contained in fuel and a temperature for operating
the fuel cell based on the temperature and the methanol
concentration used for the measurement of the J.sub.GDL and the
J.sub.PEM; and (c) generating power at the temperature determined
in the step (b) by feeding fuel containing methanol at the
concentration determined in the step (b) to the anode.
[0023] While the novel features of the invention are set forth
particularly in the appended claims, the invention, both as to
organization and content, will be better understood and
appreciated, along with other objects and features thereof, from
the following detailed description taken in conjunction with the
drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0024] FIG. 1 is a schematic vertical cross sectional view of a
unit cell incorporated in a fuel cell according to an embodiment of
the present invention.
[0025] FIG. 2 is a partially enlarged view of the membrane
electrode assembly (MEA) of the unit cell shown in FIG. 1.
[0026] FIG. 3 is a partially enlarged view of an MEA of a unit cell
incorporated in a fuel cell according to another embodiment of the
present invention.
[0027] FIG. 4 is a schematic diagram of an apparatus for measuring
methanol flux value.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Embodiments of the present invention will be described below
with reference to the accompanying drawings.
Embodiment 1
[0029] FIG. 1 shows a unit cell of a fuel cell according to an
embodiment of the present invention.
[0030] A unit cell 10 shown in FIG. 1 comprises an electrolyte
membrane 11, an anode 12 and a cathode 13 sandwiching the
electrolyte membrane 11. A membrane electrode assembly (MEA) is
composed of the electrolyte membrane 11, the anode 12 and the
cathode 13.
[0031] The MEA is sandwiched by an anode-side separator plate 14
and a cathode-side separator plate 15 that have electron
conductivity. On the outer surface of the separator plate 14 are
laminated an anode-side current collector plate 20, a heater 22 for
heating the MEA, an insulating plate 24 for electrically insulating
the cell from the outside, and an end plate 26. Likewise, on the
outer surface of the separator plate 15 are laminated a
cathode-side current collector plate 21, a heater 23 for heating
the MEA, an insulating plate 25 for electrically insulating the
cell from the outside, and an end plate 27. All of them are tightly
fixed by applying pressure in the laminating direction using
clamping rods (not shown in the drawing).
[0032] The anode-side separator plate 14 has a fuel flow channel 16
made of a groove for feeding a fuel to the anode and removing a
reaction product (e.g., carbon dioxide) formed on the surface to be
in contact with the anode. Likewise, the cathode-side separator
plate 15 has an oxidant flow channel 17 made of a groove for
feeding air to the anode formed on the surface to be in contact
with the cathode.
[0033] Gas sealants 18 and 19 are placed on the outer peripheries
of the anode 12 and the cathode 13, respectively, so as to prevent
a fuel and air from leaking out.
[0034] FIG. 2 is an enlarged view of the MEA described above. The
anode 12 comprises a catalyst layer 12a attached to one surface of
the electrolyte membrane 11 and a diffusion layer 12b attached to
the other surface of the catalyst layer 12a (i.e., the surface of
the catalyst layer 12a not in contact with the electrolyte membrane
11). Similarly, the cathode 13 comprises a catalyst layer 13a
attached to the other surface of the electrolyte membrane 11 and a
diffusion layer 13b attached to the other surface of the catalyst
layer 13a (i.e., the surface of the catalyst layer 13a not in
contact with the electrolyte membrane 11).
[0035] In the present invention, the anode diffusion layer 12b has
a methanol flux value J.sub.GDL of 1.times.10.sup.-5 to
5.times.10.sup.-4 mol/(cm.sup.2min.). The electrolyte membrane 11
has a methanol flux value J.sub.PEM. A product obtained by
multiplying the J.sub.PEM by the J.sub.GDL should be not greater
than 1.times.10.sup.-8 [mol/(cm.sup.2min.)].sup.2.
[0036] For example, in the case of using a fuel containing methanol
at a high concentration, or in the case of operating a fuel cell
while the fuel cell has a high temperature, a conventional anode
diffusion layer and a conventional electrolyte membrane (e.g.,
Nafion 117) allow a large amount of methanol to cross over the
membrane because the diffusion layer has a large methanol flux
value. In order to prevent the methanol crossover, it is necessary
to reduce the methanol flux value of the anode diffusion layer. In
contrast, in the case of using a fuel containing methanol at a low
concentration, or in the case of operating a fuel cell while the
fuel cell has a low temperature, the methanol flux value of the
anode diffusion layer becomes small. In this case, it is necessary
to increase the methanol flux value of the anode diffusion layer so
as to prevent power generation characteristic at a high current
density from degrading.
[0037] In the present invention, because the anode diffusion layer
and the electrolyte membrane have methanol flux values within the
above-mentioned ranges, it is possible to provide excellent power
generation characteristic regardless of whether the methanol
concentration of fuel is high or low, or whether the operating
temperature of the fuel cell is high or low. In other words,
because the anode diffusion layer 12b and the electrolyte membrane
11 have methanol flux values within the above-mentioned ranges, it
is possible to ensure that a sufficient amount of fuel is supplied
to the catalyst layer at any operating temperature and at any
methanol concentration. That is, both the reduction of
concentration polarization and the reduction of methanol crossover
can be achieved simultaneously.
[0038] When the anode diffusion layer 12b has a methanol flux value
J.sub.GDL of less than 1.times.10.sup.-5 mol/(cm.sup.2min.), the
supply rate of fuel to the anode catalyst layer 12a is low, and
power generation characteristic at a high current density degrades
significantly. When the anode diffusion layer 12b has a methanol
flux value J.sub.GDL of greater than 5.times.10.sup.-4
mol/(cm.sup.2min.), the supply of fuel to the anode catalyst layer
12a is nonuniform. To be more specific, the fuel supply becomes
excessive at the upstream side of the fuel flow channel whereas the
fuel supply becomes insufficient at the downstream side of the fuel
flow channels. As a result, the power generation characteristic
degrades. This behavior is particularly noticeable when the amount
of fuel supplied to the fuel cell is small.
[0039] When the product obtained by multiplying the methanol flux
value J.sub.GDL of the diffusion layer 12b by the methanol flux
value J.sub.PEM of the electrolyte membrane 11 (i.e.,
J.sub.GDL.times.J.sub.PEM) is greater than 1.times.10.sup.-8
[mol/(cm.sup.2min.)].sup.2, the methanol crossover is large, and
thus fuel utilization efficiency as well as power generation
characteristic degrades.
[0040] The methanol flux values of the anode diffusion layer and
the electrolyte membrane vary according to changes in the
concentration of methanol in fuel and in the operating temperature
of the fuel cell. For this reason, the methanol flux values of the
anode diffusion layer and the electrolyte membrane are preferably
within the above ranges in an intended methanol concentration and
operating temperature.
[0041] In the present invention, the methanol flux value of the
anode diffusion layer J.sub.GDL may be adjusted relative to the
methanol flux value J.sub.PEM of the electrolyte membrane such that
the product of J.sub.PEM and J.sub.GDL as well as the value of
J.sub.GDL fall within the above-mentioned ranges. Alternatively, on
the assumption that the J.sub.GDL of the anode diffusion layer is
1.times.10.sup.-5 to 5.times.10.sup.-4 mol/(cm.sup.2min.), an
electrolyte membrane having a J.sub.PEM that yields a product
J.sub.PEM.times.J.sub.GDL of not greater than 1.times.10.sup.-8
[(mol/cm.sup.2min.)].sup.2 may be selected.
[0042] The methanol flux value of the anode diffusion layer can be
adjusted as follows, for example.
[0043] The methanol flux value of the anode diffusion layer 12b may
be adjusted by, for example, changing the thickness of the
diffusion layer 12b. The thickness of the diffusion layer 12b is
preferably 100 to 500 .mu.m. When the diffusion layer 12b has a
thickness within this range, the balance among diffusibility of
fuel, removability of carbon dioxide and electron conductivity can
be optimized.
[0044] The diffusion layer 12b can be made of, for example, a
conductive porous material having excellent diffusibility of fuel,
removability (permeability) of carbon dioxide and electron
conductivity. Specific examples of such material include carbon
paper and carbon cloth.
[0045] Alternatively, the methanol flux value of the anode
diffusion layer 12b can be adjusted by forming a surface layer 30
having a porous structure on a surface of the diffusion layer 12b,
as shown in FIG. 3 in which the same reference numbers are given to
the same components of FIG. 2. FIG. 3 shows a case in which the
surface layer 30 is formed on each surface of the diffusion layer
12b.
[0046] In the case of forming a surface layer on a surface of the
anode diffusion layer, the methanol flux value J.sub.GDL of the
anode diffusion layer can be adjusted by, for example, changing the
surface property, porosity and thickness of the surface layer.
[0047] The surface layer 30 having a porous structure can be made
of, for example, a water repellent resin fine particle and a water
repellent binder material. Examples of the water repellent resin
fine particle include polytetrafluoroethylene (PTFE) resin fine
particle and tetrafluoroethylene-hexafluoropropylene copolymer
(FEP) resin fine particle. Examples of the water repellent binder
material include fluorocarbon resin and silicon resin.
[0048] Since the water repellent resin fine particle and the water
repellent binder material are contained, a surface layer having
extremely high water repellency (i.e., extremely low surface
energy) and a macro-porous structure is formed on the surface of
the diffusion layer. Thereby, it is possible to control the flux
value of fuel, at which the fuel permeates the entire diffusion
layer, to be uniform. Accordingly, even when an electrolyte
membrane having a high methanol flux value is used, it is possible
to ensure that a certain amount of fuel is supplied into the
catalyst layer, at the same time, the reduction of methanol
crossover can be achieved. In this case, even if the surface layer
is thin, sufficient effect can be obtained. The surface of the
surface layer containing the water repellent resin fine particle
and the water repellent binder material and the inner wall of pores
of a first layer has asperities resulting from the shape of the
water repellent resin particle (i.e., a fractal surface). Due to
the asperity, the water repellency is further enhanced, resulting
in super-water repellency. For this reason, even if the surface
layer is thin, power generation characteristic can be improved.
[0049] Moreover, the surface layer containing the water repellent
resin fine particle and the water repellent binder material does
not hinder the removabilitiy of reaction product (e.g., carbon
dioxide). Accordingly, a fuel cell having excellent power
generation characteristic particularly at a high current density
can be obtained.
[0050] The surface property and the porosity of the surface layer
can be controlled according to the composition of a paste
containing the water repellent resin particle and the water
repellent binder material, the concentration of solid components of
the paste, and the temperature and time necessary to dry the paste
applied onto the surface of the diffusion layer. In the case of
using an electrolyte membrane having a large methanol crossover
(i.e., having a large methanol flux value), for example, the
surface layer containing the water repellent resin fine particle
and the water repellent binder material preferably has a thickness
of 10 to 60 .mu.m because the balance between the flux value of the
fuel and the removability of carbon dioxide can be optimized.
[0051] The surface layer containing the water repellent resin fine
particle and the water repellent binder material preferably has a
porosity of 50 to 95%. The reason therefore is the same as
above.
[0052] The water repellent resin fine particle preferably has an
average particle size of 1 to 10 .mu.m.
[0053] The surface layer 30 having a porous structure may comprise,
instead of the water repellent resin fine particle and the water
repellent binder material, an electron conductive porous material
and a water repellent binder material. Examples of the water
repellent binder material are the same as given above. Examples of
the electron conductive porous material include carbon black,
activated carbon and metal oxides.
[0054] In this case also, it is possible to ensure that a certain
amount of fuel is supplied to the catalyst layer. At the same time,
the reduction of methanol crossover can be achieved.
[0055] The surface layer containing the electron conductive porous
material has excellent electron conductivity. For this reason,
there is the advantage that it is unnecessary to mask the portions
of the surface layer to be in contact with the ribs of the
separator when forming the surface layer on the surface of the
anode diffusion layer.
[0056] In the case of forming the surface layer containing the
electron conductive porous material and the water repellent binder
material on a surface of the anode diffusion layer 12b, the
methanol flux value J.sub.GDL of the diffusion layer 12b can be
adjusted by changing the porosity and the thickness of the surface
layer. The porosity of the surface layer can be controlled
according to the composition of a paste containing the electron
conductive porous material and the water repellent binder material,
the concentration of solid components of the paste, and the
temperature and time necessary to dry the paste applied onto the
surface of the diffusion layer.
[0057] In the case of using an electrolyte membrane having a large
methanol crossover, for example, the surface layer containing the
electron conductive porous material and the water repellent binder
material preferably has a thickness of 20 to 100 .mu.m. The surface
layer preferably has a porosity of 35 to 85%. The reason therefor
is the same as above.
[0058] The surface layer 30 can be formed as follows, for
example.
[0059] A water repellent paste composed mainly of a water repellent
resin fine particle (e.g., polytetrafluoroethylene (PTFE) resin
fine particle or tetrafluoroethylene-hexafluoropropylene copolymer
(FEP) resin fine particle) and a water repellent binder material
(e.g., fluorocarbon resin or silicon resin) is applied onto a
surface of the anode diffusion layer by spray coating, followed by
drying, whereby the surface layer 30 can be formed.
[0060] Alternatively, the surface layer 30 can be formed by
applying a paste composed mainly of a conductive carbon particle
and the water repellent resin fine particle onto a surface of the
diffusion layer 12b by wet application, and drying the paste.
[0061] The surface layer 30 may be formed on each surface of the
anode diffusion layer 12b, or it may be formed only on one surface
of the anode diffusion layer 12b. In the case of forming the
surface layer 30 only on one surface of the diffusion layer 12b,
the surface layer 30 may be formed on the surface of the diffusion
layer 12b to be in contact with the separator 14, or on the surface
of the diffusion layer 12b to be in contact with the catalyst layer
12a.
[0062] The surface layer 30 may be a single layer, or it may be
formed of two layers or more. The surface layer 30 may comprise,
for example, a layer containing a water repellent resin fine
particle and a water repellent binder material and a layer
containing an electron conductive porous material and a water
repellent binder material.
[0063] Preferably, the anode diffusion layer 12b has an air
permeability Q.sub.Air of 200 to 1000 cc/(cm.sup.2min.kPa). When
the anode diffusion layer 12b has an air permeability within the
range, the removability (gas permeability) of carbon dioxide gas
produced at the cathode can be improved.
[0064] Similar to the case of adjusting the methanol flux value of
the diffusion layer 12b, the air permeability of the diffusion
layer 12b can be adjusted by changing the thickness and the
material of the diffusion layer 12b. In the case of forming the
surface layer 30 on a surface of the diffusion layer 12b, the air
permeability of the diffusion layer 12b can be adjusted by changing
the composition material, surface property, porosity and thickness
of the surface layer 30.
[0065] When the air permeability Q.sub.Air is less than 200
cc/(cm.sup.2min.kPa), because the permeability of carbon dioxide is
low, power generation characteristic at a high current density
degrades. When the air permeability Q.sub.Air is greater than 1000
cc/(cm.sup.2min.kPa), current collecting efficiency degrades.
[0066] In order to ensure removability of carbon dioxide when the
surface layer formed on a surface of the diffusion layer contains
an electron conductive porous material and a water repellent binder
material, the ratio of the electron conductive porous material and
the water repellent binder material contained in the surface layer,
the thickness of the surface layer, etc, is preferably optimized.
For example, the ratio of the electron conductive porous material
and the water repellent binder material contained in the surface
layer is preferably 5:1 to 1:5. The surface layer preferably has a
thickness of 20 to 100 .mu.m as stated previously. As for the
electrolyte membrane 11, the membrane should have excellent proton
conductivity, thermal resistance and chemical stability. At the
same time, the electrolyte membrane 11 should have a methanol flux
value that yields a product J.sub.PEM.times.J.sub.GDL of not
greater than 1.times.10.sup.-8 [(mol/cm.sup.2min.)].sup.2. The
electrolyte membrane 11 may be made of any material as long as the
material has the above properties.
[0067] As the anode catalyst layer 12a and the cathode catalyst
layer 13a, a thin film composed mainly of a polymer electrolyte and
a conductive carbon particle or catalyst metal fine particle
carrying a catalyst metal can be used. An example of the catalyst
metal for the catalyst layer 12a is a platinum (Pt)-ruthenium (Ru)
alloy fine particle. An example of the catalyst metal for the
catalyst layer 13a is a Pt fine particle. The polymer electrolyte
contained in the catalyst layer may be the same as that of the
electrolyte membrane 11 or other polymer electrolyte. Preferred is
the same polymer electrolyte as that of the electrolyte membrane
11.
[0068] The cathode diffusion layer 13b can be made of a conductive
porous material having air diffusibility, removability of water
generated during power generation and electron conductivity.
Examples of such material include carbon paper and carbon
cloth.
[0069] The separators 14 and 15 can be made of an air-tight,
electron conductive and electrochemically stable material. The
separators may be made of any type of material as long as the
material has the above-described properties. The shape of the flow
channel 16 formed on the separator 14 and that of the flow channel
17 formed on the separator 15 are not specifically limited. Any
conventional shape known in the pertinent art can be used.
[0070] A description will be given of a method for measuring the
methanol flux value and the air permeability.
(1) Methanol Flux Value
[0071] Methanol flux value can be measured using an H-shaped cell
40 made of glass as shown in FIG. 4.
[0072] A sample 41 (diffusion layer or electrolyte membrane) is
fixed with ring-shaped rubber sheets 42 and 43 between pipes 48 and
49 of the H-shaped cell 40 in a thermostatic chamber having the
same temperature as the fuel cell operating temperature.
[0073] Subsequently, an aqueous solution of methanol 50 having a
certain methanol concentration is admitted to a first glass vessel
44, and ion exchange water 51 is admitted to a second glass vessel
45. The concentration of methanol in the aqueous solution of
methanol should be the same as that of methanol contained in the
fuel to be supplied to a fuel cell. The aqueous solution of
methanol and the ion exchange water are stirred by stirrers 46 and
47, respectively, at a certain rate, during which about 1 cc of the
aqueous solution held in the second glass vessel 45 is taken at
predetermined time intervals for gas chromatography analysis to
quantify the concentration of methanol contained in the sampling
solution. Methanol flux value can be calculated from the increased
amount of methanol per unit time.
(2) Air Permeability
[0074] In the present invention, the air permeability of the anode
diffusion layer means the rate at which air permeates through the
anode diffusion layer at room temperature. The air permeability of
the diffusion layer can be measured by, for example, a physical
property measuring instrument (e.g., Perm Porometer available from
Porous Materials, Inc.). A sample having a certain area is held
between two pressing plates, each having a channel for flowing air,
at a certain pressure. Under the compressed condition, the pressure
difference between at the air-supply side and at the air-permeation
side is increased to a maximum, during which the air flux values
are measured. The measured air flux values are plotted against the
pressure difference to obtain a straight line that most clearly
shows the measured values. The slope of the straight line is then
calculated. The obtained slope can be interpreted as air
permeability.
[0075] Note that the pressure for pressing the sample should be the
same as that applied when the separators and the MEA are
clamped.
[0076] The porosity of the surface layer can be calculated from,
for example, the composition ratio of the materials forming the
surface layer, the specific gravities of the materials, the amount
of the surface layer applied to a unit area and the thickness of
the surface layer. When the surface layer comprises a component A
having a specific gravity of R.sub.A (g/cm.sup.3) and a component B
having a specific gravity of R.sub.B (g/cm.sup.3), the amount of
the surface layer applied to a unit area is w (g/cm.sup.2), the
thickness of the surface layer is T (cm), and the composition ratio
of the components A and B is a:b, the porosity of the surface layer
can be calculated by the following equation:
{1-[w.times.(a/(a+b))/R.sub.A+w.times.(b/(a+b))/R.sub.B]/(1.times.1.times-
.T)}.times.100.
[0077] The fuel cell of the present invention can generate power as
follows, for example.
[0078] Firstly, an anode diffusion layer and an electrolyte
membrane which satisfy the following conditions are selected (step
(a)). When the anode diffusion layer has a methanol flux value
J.sub.GDM, and the electrolyte membrane has a methanol flux value
J.sub.PEM, which are measured by allowing the anode diffusion layer
and the electrolyte membrane to come into contact with an aqueous
solution having a certain methanol concentration at a certain
temperature, the anode diffusion layer has a methanol flux value
J.sub.GDM of 1.times.10.sup.-5 to 5.times.10.sup.-10.sup.-4
mol/(cm.sup.2min.), and a product obtained by multiplying the
J.sub.PEM by the J.sub.GDM is not greater than 1.times.10.sup.-8
[mol/(cm.sup.2min.)].sup.2.
[0079] In this step, the methanol flux value of the anode diffusion
layer can be adjusted by changing the thickness of the anode
diffusion layer as described above and/or forming the surface layer
as described above on a surface of the diffusion layer.
[0080] Subsequently, based on the temperature and the methanol
concentration used for the measurement of methanol flux value, a
concentration of methanol to be contained in the fuel and a
temperature for operating the fuel cell are determined (step (b)).
In this step, the methanol concentration used for the measurement
of methanol flux value may be determined as methanol concentration
of fuel, and the temperature used for the measurement of methanol
flux value may be determined as operating temperature of the fuel
cell. Even if the same diffusion layers and electrolyte membranes
are used, methanol flux value varies according to the temperature
and the methanol concentration used for the measurement of methanol
flux value. For this reason, the operating temperature of the fuel
cell and the methanol concentration of fuel may be adjusted so as
to improve power generation characteristic in a range that they do
not affect the methanol flux value.
[0081] Then, electricity (power) is generated at the temperature
determined in the above step (b) by feeding a fuel containing
methanol at the concentration determined in the above step (b) to
the anode (step (c)).
[0082] As described above, even when the operation temperature of
the fuel cell and the methanol concentration of the fuel are
specified values, the methanol flux values of the anode diffusion
layer and the electrolyte membrane can be determined according to
the specified values. Thereby, the power generation characteristic
of the fuel cell can be improved.
[0083] For example, in the case of using an electrolyte membrane
having a large methanol crossover, in order to produce a small fuel
cell system and to achieve longer operation of the fuel cell
system, the concentration of methanol contained in the fuel is
preferably 4 to 6 mol/L. When the methanol concentration exceeds 6
mol/L, the methanol flux value of the electrolyte membrane becomes
significantly large. For this reason, it is difficult to
appropriately control the methanol flux value of the anode
diffusion layer.
[0084] In the case of using an electrolyte membrane having a small
methanol crossover, the concentration of methanol contained in the
fuel may be 6 mol/L or greater. In this case also, the porosity and
the thickness of the surface layer is not specifically limited as
long as they fall within the above-described ranges.
[0085] The operating temperature of the fuel cell is preferably 40
to 80.degree. C., more preferably 50 to 70.degree. C. As the
operating temperature of the fuel cell is increased, the reaction
activity of the catalyst increases, resulting in improved power
generation characteristic. However, if the operating temperature is
too high, the electronic components around the fuel cell will be
affected. Considering the power generation characteristic and the
effect on the electronic components, the above temperature range is
the best.
[0086] The present invention will be described in further detail
below with reference to examples, but it should be understood that
the present invention is not limited to the examples given
below.
EXAMPLE 1
(Fuel Cell A)
(Production of Catalyst Carrying Particle)
[0087] A catalyst-carrying particle for anode was produced by
allowing a conductive carbon particle to carry Pt and Ru each
having an average particle size of 3 nm. The amounts of Pt and Ru
were 30% of the total weight of Pt, Ru and the conductive carbon
particle.
[0088] A catalyst-carrying particle for cathode was produced by
allowing a conductive carbon particle (the same one as used above)
to carry Pt having an average particle size of 3 nm. The amount of
Pt was 50% of the total weight of Pt and the conductive carbon
particle. The conductive carbon particle used here was carbon black
having an average primary particle size of 30 nm (Ketjen black EC
available from Mitsubishi Chemical Corporation).
(Production of MEA)
[0089] Subsequently, a dispersion prepared by dispersing the
catalyst-carrying particle for anode in an aqueous solution of
isopropanol was mixed with a dispersion prepared by dispersing a
polymer electrolyte in ethanol. The obtained mixture was further
mixed by a bead mill so as to disperse the catalyst-carrying
particle for anode and the polymer electrolyte. Thereby, a paste
for anode catalyst layer was prepared. The polymer electrolyte used
here was perfluorocarbon sulphonic acid ionomer (Flemion available
from Asahi Glass Co., Ltd.). The paste for anode catalyst layer
contained the conductive carbon particle and the polymer
electrolyte at a weight ratio of 1:1.
[0090] Using the catalyst-carrying particle for cathode prepared
above, a paste for cathode catalyst layer was prepared in the same
manner as the paste for anode catalyst layer was prepared.
[0091] Each of the pastes was applied onto a
polytetrafluoroethylene sheet (Naflon PTFE sheet available from
Nichias Corporation) by a doctor blade, followed by drying in an
atmosphere at room temperature for 6 hours. Each of the obtained
catalyst sheets was cut into a size of 6 cm.times.6 cm. The cut-out
anode catalyst sheet was laminated on one surface of an electrolyte
membrane with the paste-applied surface of the anode catalyst sheet
in contact with the surface of the electrolyte membrane. On the
other surface of the electrolyte membrane was laminated the cut-out
cathode catalyst sheet with the paste-applied surface of the
cathode catalyst sheet in contact with the other surface of the
electrolyte membrane. The electrolyte membrane and the catalyst
sheets were heat-bonded by hot pressing at 125.degree. C. under a
pressure of 8 MPa for 5 minutes. The electrolyte membrane used here
was perfluoroalkylsulphonic acid ion exchange membrane (Nafion 117
available from E.I. Du Pont de Nemours & Co. Inc., USA).
[0092] The polytetrafluoroethylene sheets were then peeled from the
assembly produced above. Thereby, an anode catalyst layer and a
cathode catalyst layer were formed. The anode and cathode catalyst
layers each contained 1.8 mg/cm.sup.2 of the Pt catalyst.
[0093] As the anode diffusion layer, carbon paper (TGP-H120
available from Toray Co., Ltd. (thickness: about 360 .mu.m)) cut
into a size of 6 cm.times.6 cm was used. The portions of the anode
diffusion layer to be in contact with the ribs, each located
between adjacent flow channels, of a separator were masked. Then,
to the surface of the anode diffusion layer to be in contact with
the separator was applied a super-water repellent composed mainly
of a polytetrafluoroethylene resin fine particle and a silicon
resin (HIREC1450 available from NTT Advanced Technology
Corporation) by spray coating. The applied super-water repellent
was dried at 60.degree. C. for 30 minutes. Thereby, a surface layer
(hereinafter referred to as first layer) containing the super-water
repellent was formed on the surface of the diffusion layer. The
formed first layer had a thickness of about 20 .mu.m and a porosity
of 77.0%. The first layer had a fractal surface. Note that the
formation of the first layer in the examples below was carried out
in the same manner as above.
[0094] As the cathode diffusion layer, carbon paper (TGP-H060
available from Toray Co., Ltd. (thickness: about 180 .mu.m)) cut
into a size of 6 cm.times.6 cm was used.
[0095] Subsequently, the anode diffusion layer was laminated on the
surface of the electrolyte membrane having the anode catalyst layer
formed thereon. The cathode diffusion layer was laminated on the
other surface of the electrolyte membrane having the cathode
catalyst layer formed thereon. The diffusion layers were bonded to
the catalyst layers by hot pressing at 125.degree. C. under a
pressure of 4 MPa for 3 minutes.
[0096] Finally, gas sealants were placed on the outer peripheries
of the anode and the cathode, and heat sealing was performed at
135.degree. C. under a pressure of 4 MPa for 30 minutes. Thereby,
an MEA was produced.
[0097] The obtained MEA was then sandwiched by separators having an
outer size of 10 cm.times.10 cm and a thickness of 4 mm, current
collector plates, heaters, insulating plates and end plates. The
whole was then fixed with clamping rods. The clamping pressure used
here was 20 kgf/cm.sup.2 per unit area of the separator. The
separators had a serpentine flow channel having a width of 1.5 mm
and a depth of 1 mm formed on the surface thereof. The current
collector plates and the end plates used here were made of a
stainless steel plate plated with gold.
[0098] A fuel cell comprising the unit cell produced in the manner
described above was denoted as cell A.
(Fuel Cell B)
[0099] A fuel cell B was produced in the same manner as the fuel
cell A was produced except that a surface layer comprising a
mixture of carbon black (CB) and a polytetrafluoroethylene (PTFE)
resin fine particle was formed on the surface of the anode
diffusion layer to be in contact with the anode catalyst layer. The
thickness of the surface layer was about 50 .mu.m.
[0100] The surface layer was produced as follows.
[0101] Firstly, carbon black (XC-72R available from CABOT
Corporation) was ultrasonically dispersed in an aqueous solution
having a surfactant (Triton X-100 available from Sigma-Aldrich,
Inc.) added thereto, after which the mixture was further mixed by a
mixer (HIVIS MIX available from Tokushu Kika Kogyo Co, Ltd) so as
to bring the carbon black into a highly dispersed state. A
polytetrafluoroethylene dispersion (D-1E available from Daikin
Industries, Ltd.) was then added to the above mixture, which was
further mixed to bring the mixture into a highly dispersed state.
Thereby, a paste was prepared. The paste contained the carbon
black, polytetrafluoroethylene and the surfactant at a weight ratio
of 10/3/1.
[0102] The obtained paste was uniformly applied onto the entire
surface of carbon paper by a doctor blade, followed by drying in an
atmosphere at room temperature for 8 hours, which was then baked at
360.degree. C. in an inert gas (N.sub.2) atmosphere for 1 hour to
remove the surfactant. Thereby, a surface layer (hereinafter
referred to as second layer) containing the CB and (PTFE) resin
fine particles was formed. The second layer had a porosity of
65.1%. Note that the formation of the second layer in the examples
below was carried out in the same manner as above.
(Fuel Cell C)
[0103] A second layer having a thickness of about 30 .mu.m was
first formed on the surface of the anode diffusion layer to be in
contact with a separator. On the second layer was further formed a
first layer having a thickness of about 20 .mu.m. Thereby, a
surface layer comprising the first and second layers was formed.
Using the thus-produced anode diffusion layer, a fuel cell C was
produced in the same manner as the fuel cell A was produced. The
first and second layers had a porosity of 77.0% and 62.8%,
respectively. The first layer had a fractal surface.
(Fuel Cell D)
[0104] A fuel cell D was produced in the same manner as the fuel
cell C was produced except that the second layer had a thickness of
about 50 .mu.m and that the first layer had a thickness of about 30
.mu.m. The first and second layers had a porosity of 78.5% and
65.1%. The first layer had a fractal surface.
(Fuel Cell E)
[0105] A fuel cell E was produced in the same manner as the fuel
cell A was produced except for the following.
[0106] As the electrolyte membrane, a hydrocarbon polymer
electrolyte membrane composed mainly of sulfonated
polyether-etherketon (PEEK) having a thickness of 100 .mu.m was
used. As the anode diffusion layer, carbon paper (TGP-H060
available from Toray Co., Ltd.) was used. On the surface of the
diffusion layer to be in contact with the catalyst layer was formed
a second layer having a thickness of about 5 .mu.m. The second
layer had a porosity of 58.1%.
(Fuel Cell F)
[0107] A fuel cell F was produced in the same manner as the fuel
cell A was produced except that a hydrocarbon polymer electrolyte
membrane composed mainly of sulfonated polyether-etherketon (PEEK)
having a thickness of 60 .mu.m was used as the electrolyte
membrane, and that the surface layer was not formed on the surface
of the anode diffusion layer.
(Comparative Fuel Cell 1)
[0108] A comparative fuel cell 1 was produced in the same manner as
the fuel cell A was produced except that the surface layer was not
formed on the surface of the anode diffusion layer.
(Comparative Fuel Cell 2)
[0109] A comparative fuel cell 2 was produced in the same manner as
the fuel cell A was produced except that carbon paper (TGP-H060
available from Toray Co., Ltd.) was used as the anode diffusion
layer, and that the surface layer was not formed on the surface of
the anode diffusion layer.
(Comparative Fuel Cell 3)
[0110] A comparative fuel cell 3 was produced in the same manner as
the fuel cell A was produced except that a first layer having a
thickness of about 80 .mu.m was formed on the surface of the anode
diffusion layer to be in contact with a separator. The first layer
had a porosity of 79.8% and a fractal surface.
(Comparative Fuel Cell 4)
[0111] A comparative fuel cell 4 was produced in the same manner as
the fuel cell A was produced except for the following.
[0112] As the electrolyte membrane, a hydrocarbon polymer
electrolyte membrane composed mainly of sulfonated
polyether-etherketon (PEEK) having a thickness of 60 .mu.m was
used. A second layer having a thickness of about 80 .mu.m was
formed on the surface of the anode diffusion layer to be in contact
with a separator. On the second layer was further formed a first
layer having a thickness of about 50 .mu.m. Thereby, a surface
layer comprising the first and second layers was formed on the
surface of the anode diffusion layer. The first and second layers
had a porosity of 80.6% and 66.8%, respectively. The first layer
had a fractal surface.
[0113] Table 1 shows the type of the electrolyte membrane and the
composition of the surface layer formed on the surface of the anode
diffusion layer for the fuel cells A to F and the comparative fuel
cells 1 to 4. TABLE-US-00001 TABLE 1 Surface layer formed
Electrolyte membrane Fuel cell A First layer (20 .mu.m)
Perfluorocarbon sulfonic acid membrane Fuel cell B Second layer (50
.mu.m) Perfluorocarbon sulfonic acid membrane Fuel cell C First
layer (20 .mu.m) + Perfluorocarbon sulfonic acid Second layer (30
.mu.m) membrane Fuel cell D First layer (30 .mu.m) +
Perfluorocarbon sulfonic acid Second layer (50 .mu.m) membrane Fuel
cell E Second layer (5 .mu.m) Hydrocarbon polymer electrolyte
membrane (sulfonated PEEK) Fuel cell F None Hydrocarbon polymer
electrolyte membrane (sulfonated PEEK) Comp. None Perfluorocarbon
sulfonic acid Fuel cell 1 membrane Comp. None Perfluorocarbon
sulfonic acid Fuel cell 2 membrane Comp. First layer (80 .mu.m)
Perfluorocarbon sulfonic acid Fuel cell 3 membrane Comp. First
layer (50 .mu.m) + Hydrocarbon polymer electrolyte Fuel cell 4
Second layer (80 .mu.m) membrane (sulfonated PEEK)
[0114] The electrolyte membranes and the anode diffusion layers of
the fuel cells A to F and the comparative fuel cells 1 to 4 were
analyzed for methanol flux value according to the procedure
described previously, and the anode diffusion layers were
additionally analyzed for air permeability according to the
procedure described previously.
[0115] In the methanol flux value measurement, the methanol
concentration of the aqueous solution of methanol used for the
measurement was set at 6 mol/L. The thermostatic chamber was
maintained at a temperature of 60.degree. C. The openings of the
ring-shaped rubber sheets had an area of 3.14 cm.sup.2. The first
glass vessel 44 contained 50 cc of an aqueous solution of methanol.
The second glass vessel 45 contained 200 cc of ion exchange
water.
[0116] In the air permeability measurement, the sample had an area
of 7 cm.sup.2. The pressure for pressing the sample was set at 20
kgf/cm.sup.2. The pressure difference between at the air-supply
side and at the air-permeation side of the sample was increased to
3 kPa at the maximum. The obtained results are shown in Table 2.
TABLE-US-00002 TABLE 2 J.sub.GDL J.sub.PEM J.sub.GDL .times.
J.sub.PEM Q.sub.AIR (mol/ (mol/ ([mol/ (cc/(cm.sup.2 (cm.sup.2
min.)) (cm.sup.2 min.)) (cm.sup.2 min.)].sup.2) min. kPa)) Fuel
cell A 5.6 .times. 10.sup.-5 8.9 .times. 10.sup.-5 5.0 .times.
10.sup.-9 490 Fuel cell B 9.3 .times. 10.sup.-5 8.9 .times.
10.sup.-5 8.3 .times. 10.sup.-9 280 Fuel cell C 3.7 .times.
10.sup.-5 8.9 .times. 10.sup.-5 3.3 .times. 10.sup.-5 360 Fuel cell
D 1.0 .times. 10.sup.-5 8.9 .times. 10.sup.-5 .sup. 8.9 .times.
10.sup.-10 200 Fuel cell E 5.0 .times. 10.sup.-4 2.0 .times.
10.sup.-5 1.0 .times. 10.sup.-8 1000 Fuel cell F 2.7 .times.
10.sup.-4 3.4 .times. 10.sup.-5 9.2 .times. 10.sup.-9 510 Comp.
Fuel 2.7 .times. 10.sup.-4 8.9 .times. 10.sup.-5 2.4 .times.
10.sup.-8 510 cell 1 Comp. Fuel 5.4 .times. 10.sup.-4 8.9 .times.
10.sup.-5 4.8 .times. 10.sup.-8 1140 cell 2 Comp. Fuel 7.3 .times.
10.sup.-6 8.9 .times. 10.sup.-5 .sup. 6.5 .times. 10.sup.-10 390
cell 3 Comp. Fuel 5.1 .times. 10.sup.-6 3.4 .times. 10.sup.-5 .sup.
1.7 .times. 10.sup.-10 110 cell 4
[0117] Subsequently, the fuel cells A to F and the comparative fuel
cells 1 to 4 were analyzed for current-voltage characteristic in
the manner described below.
[0118] Each fuel cell was continuously operated at a current
density of 100 mA/cm.sup.2 or 200 mA/cm.sup.2 at a cell temperature
of 60.degree. C. for 15 minutes while an aqueous solution of
methanol at a concentration of 6 mol/L was fed to the anode at a
flow rate of 1 cc/min and air was fed to the cathode at a flow rate
of 1 L/min. During the continuous operation, the effective voltage
was measured. The results are shown in Table 3. TABLE-US-00003
TABLE 3 Current-voltage characteristic Voltage at 100 mA/cm.sup.2
(V) Voltage at 200 mA/cm.sup.2 (V) Fuel cell A 0.458 0.346 Fuel
cell B 0.426 0.305 Fuel cell C 0.442 0.324 Fuel cell D 0.376 0.258
Fuel cell E 0.384 0.286 Fuel cell F 0.411 0.292 Comp. Fuel 0.205
Unable to retain voltage cell 1 Comp. Fuel 0.138 Unable to retain
voltage cell 2 Comp. Fuel 0.321 0.177 cell 3 Comp. Fuel 0.246 0.112
cell 4
[0119] In each of the fuel cells A to F, because the physical
properties of the anode diffusion layer and the electrolyte
membrane were optimized to suit the fuel cell operating conditions
(the use of an aqueous solution of methanol at a concentration of 6
mol/L as the fuel, and an operating temperature of 60.degree. C.),
it was possible to reduce methanol crossover, to ensure a
sufficient amount of fuel supplied to the anode catalyst layer, and
to improve the carbon dioxide gas removability of the anode
diffusion layer, all simultaneously. As evident from Table 3, the
fuel cells had excellent power generation characteristic
particularly at a higher current density without impairing the fuel
utilization efficiency.
[0120] In the comparative fuel cells 1 and 2, on the other hand, in
which the electrolyte membrane having a large methanol crossover
and the thin anode diffusion layer were used, the product obtained
by multiplying the methanol flux value of the electrolyte membrane
by that of the anode diffusion layer (i.e., the product of
J.sub.GLD.times.J.sub.PEM) was over 1.times.10.sup.-8
[(mol/cm.sup.2min.)].sup.2. In other words, the amount of methanol
crossing through the membrane from the anode to the cathode
increased significantly. This led to the degradation of power
generation characteristic (the voltage was unable to be retained at
a current density of 200 mA/cm.sup.2). The degradation of power
generation characteristic was more remarkable in the comparative
battery 2 having a methanol flux value J.sub.GDL of greater than
5.times.10.sup.-4 mol/(cm.sup.2min.).
[0121] In the comparative fuel cells 3 and 4, the product of
J.sub.GDL.times.J.sub.PEM was small, and the reduction of methanol
crossover was achieved. However, the anode diffusion layer had a
methanol flux value of less than 1.times.10.sup.-5
mol/(cm.sup.2min.). Because of this, the supply rate of the fuel to
the anode catalyst layer was lower than the consumption rate of the
fuel during power generation at a higher current density, and
therefore the power generation characteristic at a higher current
density was significantly low. The comparative fuel cell 4 in which
the thick surface layer was formed on the surface of the anode
diffusion layer, in particular, had a low air permeability
Q.sub.air of less than 200 cc/(cm.sup.2min.kPa), and thus the
removability of carbon dioxide in the anode diffusion layer was
poor. Presumably, this is one of the factors that significantly
degraded power generation characteristic at a higher current
density.
[0122] A comparison between the fuel cells A and B shows that the
fuel cell A exhibited improved power generation characteristic
although the surface layer of the fuel cell A was thinner. This can
be explained as follows. The first layer was an aggregate of the
water repellent resin fine particles formed by deposition of the
particles on the diffusion layer, so that there was asperities
derived from the shape of the water repellent resin fine particle
(fractal surface) in the surface of the first layer and the inner
wall of pores of the first layer. Due to the asperity of the
surface of the first layer and the inner wall of pores of the first
layer, the water repellency was improved, exhibiting the
super-water repellency. For this reason, the fuel cell A exhibited
improved power generation characteristic although the surface layer
of the fuel cell A was thinner.
[0123] Although the present invention has been described in terms
of the presently preferred embodiments, it is to be understood that
such disclosure is not to be interpreted as limiting. Various
alterations and modifications will no doubt become apparent to
those skilled in the art to which the present invention pertains,
after having read the above disclosure. Accordingly, it is intended
that the appended claims be interpreted as covering all alterations
and modifications as fall within the true spirit and scope of the
invention.
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